Step by Step Mini Toolbox

*I Do not claim ownership or invention of this project* First Saw the Project here: http://alphamom.com/family-fun/holidays/surprise-dad-with-the-smallest-toolbox-ever

Mini Toolbox!!

I thought this idea was cute and creative. It also seem timely and a great gift for upcoming fathers day! Here we go!

SUPPLIES YOU WILL NEED:

TWO Mint Cans (Original size is what I purchased, theoretically you could use the small cans as well.)

ONE "Rope Eye Strap" 1 3/4" wide Stainless Steel , this item is technically boat hardware. All ace hardwares carry them in their warehouse, if they don't already have them in stock.

TWO '3/8"x 6 x 32 thread, stainless flat head machine Screws. (Stainless is optional and typically more expensive because they don't rust as fast as zinc coated hardware).

TWO '6 x 32 thread, stainless hex head nuts. I chose the size 6 screw and nut because its what fit best in my strap. Depending on manufacturer different sizes may work better.
ONE eight penny nail (Finish doesn't matter. ONE size 17 wire brad nail (Length and finish doesn't matter). ONE: Hammer. ONE: Set wire cutters or diagonal pliers.

26 Gauge Wire, I used red wire I got from the craft store because I thought it looked cooler but any type of wire will work as long as its the right gauge. Will discuss how much length you need below. Probably should buy a roll, typically pretty cheap.

Now brand and color of spray paint vary by store and preference, but here's why I like these two brands. The Rustoleum 'Clean Metal Primer' is a great product that has good solid levels and helps prevent rust. I chose the Ace Premium Enamel brand because I love the spray head for small projects, its kind of a fan spray and you can turn it to spray vertically or horizontally. It comes in handy when you have clean lines and edges you have to work with. The color I chose was glossy 'Banner Red' because typically tool boxes are red, but whatever color or sheen finish you choose will work. I plan on making a hardware princess version also. PINK Pink Pink!

DISASSEMBLING YOUR MINT CANS: If you check out your can you'll notice that the lid of the can is held to the bottom by two thin metal tension flaps. Use a small flat head screw driver or your finger nails

(I used this method because the metal is extremely easy to bend back) to pull the flaps back enough to slip the lid off. Leave the flaps in the pulled back position until your ready to re-assemble.

If it wasn't obvious from the beginning the rope eye strap is what I used for my toolbox handle. Choose one of the can lids to be your top, put the other lid and bottoms aside until later. Luckily I was able to use the graphics on the can to help line up my lid handle. You could hammer form the top but I was worried that I would squish my lid so I flipped it over to line it up.

The advantage to doing this is that you have a little of a homemade metal grommet to help you hold and line up your handle for later when you screw it on you can see that in the last picture of the series. Whe you have your handle lined up where you want it take your 8 penny nail and hammer two holes on your lid. Make sure you have something to hammer on. I used a reed trivet which worked nicely and I didn't destroy my cutting board.

I took a video of the next step. View it here.

WRITTEN DIRECTIONS:
Take your remaining lid and choose a bottom. Turn your lid upside down and place your can bottom inside. Hammer 2-4 holes from inside the can bottom with your wire brad through both the can bottom and the lid. This way even when you flip them around the holes will still line up. Then mock assemble your cans to make sure you get your order down before you do your final assembly.

Ok so next step is paint. Find a well ventilated area (preferably outside) and flip your bottoms upside down and your lids right side up. Spray an even layer of primer and wait 15-20 of drying time. Make sure you check directions on your can. I didn't do any sanding or chemical prep on my cans. When primer is finished apply even coat of color. Wait to dry 15-20 minutes. Apply second coat if necessary or preferred. I only applied one coat of the red. When everything is finished drying line them up in order of assembly and get your wire ready.

FINAL ASSEMBLY: Again. make sure you have your can order correct. Attach your Bottom w/ no holes in it to lid with four brad nail holes.Push the tension flaps back in place over the lid hinge pins. Next Take two 6 inch lengths of wire and wire your top can bottom to the TOP of your bottom can lid. On the inside of your BOTTOM lid pull lengths of wire together and twist tightly for closer. Wether you leave the extra length or snip them shorter is your preference.

Wire the lengths through the inside of your TOP can Bottom so it looks neat from the inside.

Next attach your TOP lid to your TOP Bottom. Push the tensions flaps back in place over the lid hinge pins.

Next, get your mini handle (rope eye strap) and line it up on the nail grommet holes.

Take your machine screws and screw them through the lid.

Next, screw on your nuts and tighten down to hold handle in place snugly. I used the screwdriver to hold my screws in place while I threaded on the nuts then used my pliers to give the nuts an extra twist (BAH! :).

Now your toolbox is FINISHED! YEEEEEEEEEE! View from the front.

And View from the back!

SOME PROJECT MODIFICATION SUGGESTIONS: After about five minutes of playing with my toolbox my wire started to loosen making my cans wobbly. I disassembled them and used some very thin double sided foam tape to help keep the two cans attached together more snugly. If I were to make another one I might go as far as to use size 4 machine screws and nuts to just attach them together instead of wire. But I like the way the wire looks so I left it. But explore your options and know that you have more than one.

A NOTE ABOUT THE PAINTING: You may notice after playing with your toolbox that every time you open and close your lid some of your spray paint comes off. You can't see this when your lids are closed, but if your OCD like me it will probably bug you. I suggest using a thin 3/4" masking tape (Just the regular cheap stuff, you don't need the expensive blue or green stuff) and tape off the top of your can BOTTOMS before you paint them to prevent this. Tape off just the distance that the lid settles onto the bottom.

LAST BUT NOT LEAST: You can totally fill this will cool stuff dad/mom/anyone would love, or hodge pog pictures inside, or use it as a holder for a Hardware STore gift card! Happy SUmmer!